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Thread: Mike's Kitfox IV rebuild

  1. #31
    Senior Member bbs428's Avatar
    Join Date
    Jan 2015
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    Webb City, MO
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    240

    Default Re: Mike's Kitfox IV rebuild

    That's some nice work on your new windscreen. The light smoke imho is just the right amount of tint. Looks perfect!
    Somebody said that carrier pilots were the best in the world, and they must be or there wouldn't be any of them left alive. ó Ernie Pyle

    Brett Butler
    Building: Model 5 Outback with 7 mods

  2. #32

    Join Date
    Oct 2018
    Location
    Kitchener, Ontario
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    59

    Default Re: Mike's Kitfox IV rebuild

    Rudder Peddle Reinforcement Kit.

    Thanks Kitfox... this sure makes it easy.

    Still have to glue in the sleeves and paint the brackets, Just test fitting here and showing you all the complete kit (M1-C4) from the factory.






    Screen Shot 2019-12-21 at 11.25.07 PM.jpg

  3. #33

    Join Date
    Oct 2018
    Location
    Kitchener, Ontario
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    59

    Default Re: Mike's Kitfox IV rebuild

    Under Seat Storage installed.

    Had to repair some of the previous "repairs" prior to final installation (The very dark brown fibreglass wasn't me) and fix some other cracks in the seat pan.

    I think every Kitfox should have these storage boxes installed or at least some sort of butt blocker, seeing the shape this seat pan was in, one hard landing or opps and you loose some of your flight controls, It's great insurance, and adds a handy storage area.

    Bottom View:

    Screen Shot 2020-01-03 at 5.44.19 PM.jpg

    Top View:

    Screen Shot 2020-01-03 at 5.44.29 PM.jpg

    Test Fit with scrap lexan lid (Old windshield), Final version of the lid will be done with leftover tinted lexan from the windshield

    Screen Shot 2020-01-03 at 5.44.40 PM.png

  4. #34

    Join Date
    Oct 2018
    Location
    Kitchener, Ontario
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    59

    Default Re: Mike's Kitfox IV rebuild

    Time for the wheels.

    Nanco N800 21 x 12 x 8 on the right.

    Screen Shot 2020-01-03 at 5.53.18 PM.jpg

    Mounted: Thankfully they round out a bit. was a bit worried when they arrived

    Screen Shot 2020-01-03 at 5.54.13 PM.png

    Unfortunately I cannot install the tires, Seems the past few owners have neglected checking the inner wheel bearings for the past 24 years, I've ordered new inner and outers

    Screen Shot 2020-01-03 at 5.55.52 PM.png

    outer vs inner wheel bearings. F-It ordered 4 new ones
    Screen Shot 2020-01-03 at 5.56.49 PM.png

  5. #35
    Senior Member
    Join Date
    Feb 2011
    Location
    Dupuy,Qc
    Posts
    304

    Default Re: Mike's Kitfox IV rebuild

    Wowww nice job..i need these to..thankís for good pic

  6. #36

    Join Date
    Oct 2018
    Location
    Kitchener, Ontario
    Posts
    59

    Default Re: Mike's Kitfox IV rebuild

    Seems my Kitfox 4 came with shielded spark plug wires. The shield grounds to the ignition box behind the firewall ( box houses the coils and mags)

    problem is I canít seem to find shielded wire anywhere. Seems Rotax stopped requiring this on the 912, I however like the idea of shielded cables

    heres said box and the spark plug wires (blue). There is a metal retaining bracket that clamps the spark plug wires to the ignition box and affectively Grounds the wires (not showed)

    IMG23.jpg

    Old wires are falling apart, time to replace:

    IMG27.png

    Heres what I did: Ordered standard Rotax Ignition wire and 3/8 shielding, put the shielding over the ignition wire, heat shrink and zip tie near the cap, shielding stops at the ground block that houses the modules.

    IMG24.png

    New Caps
    IMG25.jpg

    Ignition box. Tight fit getting all the wires back in there.

    There is more blue heat shrink covering the shielding where the wires go threw the firewall (Just as added protection)

    IMG26.png


  7. #37

    Join Date
    Oct 2018
    Location
    Kitchener, Ontario
    Posts
    59

    Default Re: Mike's Kitfox IV rebuild

    Motor mount replacement time

    Screen Shot 2020-01-17 at 12.23.26 AM.png

    Pretty easy,
    Top two come right out, The bottom bolt everyone complains about (Head of bolt is against the engine case) I found if you removed the two bottom bolts on the cradle, you can just slide the whole assembly off

    Easy peazy

    Screen Shot 2020-01-17 at 12.23.36 AM.jpg

    Jack on table, Lift a little here, lift a little there, and the rubber mounts pop right out.

    Screen Shot 2020-01-17 at 12.23.43 AM.jpg

    Bottom bolts, Remove the 2 bolts (17mm) that connect the engine cradle to the bottom of the engine block, and you can easily slide the bottom bolt right out still in the cradle

    Screen Shot 2020-01-17 at 12.23.50 AM.png

    Last edited by 4Hummer; 01-17-2020 at 07:47 AM.

  8. #38
    Senior Member Dusty's Avatar
    Join Date
    Dec 2012
    Location
    Christchurch, New Zealand
    Posts
    304

    Default Re: Mike's Kitfox IV rebuild

    If you have room put a heat shield on the lower mount(I used the curved end from an oil filter with a spacer) when I replaced mine. One disc was cooked to the point of possibly been on fire at some point. Also check the crush sleeve as there was a change of specification on length. You are gunna have soo much fun with that nice plane!

  9. #39

    Join Date
    Oct 2018
    Location
    Kitchener, Ontario
    Posts
    59

    Default Re: Mike's Kitfox IV rebuild

    Brakes Redo

    Out with the old, in with the new.

    Gotta say Matco is super awesome to deal with. New Masters, Rotors, Pads, Shorter Clevis's, and Nord lock washers (so I don't have to use safety wire)

    Screen Shot 2020-01-18 at 9.13.07 PM.jpg



    Reline tool. Don't bother with the cheaper one at aircraft spruce. This is worth the extra couple bucks,

    RAPCO BRAKE RIVET TOOL

    https://www.aircraftspruce.ca/catalo...lickkey=201929

    Screen Shot 2020-01-18 at 9.13.27 PM.png

  10. #40

    Join Date
    Oct 2018
    Location
    Kitchener, Ontario
    Posts
    59

    Default Re: Mike's Kitfox IV rebuild

    Tail wheel time.

    This setup has got to go. Look at the massive stack of washers someone used to try and fix the bent original tail spring.

    Screen Shot 2020-01-24 at 12.10.36 AM.png

    Decided on the Matco 8" Wide (single fork)
    Screen Shot 2020-01-24 at 12.08.50 AM.png

    Phat!
    Screen Shot 2020-01-24 at 12.09.06 AM.png

    Just a tad bigger....
    Screen Shot 2020-01-24 at 12.09.28 AM.png

    New Leaf springs from the wonderful people at the KitFox factory.
    Screen Shot 2020-01-24 at 12.15.10 AM.jpg

    The tricky part was getting the bolt out and replaced with a shorter one. No access hole and I didn't want to cut into the fabric. I found if you removed the access plate below the elevator you could use an inspection camera and spring loaded grappling hook to get the bolt in and out. It's very VERY frustrating but doable.

    Screen Shot 2020-01-24 at 12.18.25 AM.jpg

    Ever play that Arcade game where you try and pickup a toy with a grappling hook ? This is 100% worse than that.
    Screen Shot 2020-01-24 at 12.22.05 AM.png

    Its like playing the above game, but via a crappy camera in a cramped space, and everything is backwards
    Screen Shot 2020-01-24 at 12.24.37 AM.png

    Success
    Screen Shot 2020-01-24 at 12.23.21 AM.png

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